RALEIGH, NC—Nov. 10, 2011—Researchers from North Carolina State University have developed a simple way to convert two-dimensional patterns into three-dimensional (3D) objects using only light.

“This is a novel application of existing materials, and has potential for rapid, high-volume manufacturing processes or packaging applications,” says Dr. Michael Dickey, an assistant professor of chemical and biomolecular engineering at NC State and co-author of a paper describing the research.

The new technique can be used to create a variety of objects, such as cubes or pyramids, without ever having to physically touch the material.

The process is remarkably simple. Researchers take a pre-stressed plastic sheet and run it through a conventional inkjet printer to print bold black lines on the material. The material is then cut into a desired pattern and placed under an infrared light, such as a heat lamp.

The bold black lines absorb more energy than the rest of the material, causing the plastic to contract—creating a hinge that folds the sheets into 3D shapes. This technique can be used to create a variety of objects, such as cubes or pyramids, without ever having to physically touch the material. The technique is compatible with commercial printing techniques, such as screen printing, roll-to-roll printing, and inkjet printing, that are inexpensive and high-throughput but inherently 2D.

By varying the width of the black lines, or hinges, researchers are able to change how far each hinge folds. For example, they can create a hinge that folds 90 degrees for a cube, or a hinge that folds 120 degrees for a pyramid. The wider the hinge, the further it folds. Wider hinges also fold faster, because there is more surface area to absorb energy.

“You can also pattern the lines on either side of the material,” Dickey says, “which causes the hinges to fold in different directions. This allows you to create more complex structures.”